What is the difference between standard and custom packaging?

The main difference is not limited to the dimensions of the packaging. Protection, ease of use, lead time and costs over the entire lifecycle also play a role. The table below shows the main differences at a glance.

This does not mean that custom packaging is automatically the better choice. The right solution depends on the application, frequency of use, risks and total cost. Below, we explain when standard packaging is sufficient and when custom packaging becomes worthwhile.

Custom packaging becomes interesting as soon as a standard solution creates limitations. This may be the case with fragile or valuable equipment, unusual dimensions, intensive transport, specific handling requirements or the need to organise multiple components clearly within a single package.

With a custom solution, we do not only look at the outside of the crate or case. We design the complete packaging solution around the application. This can include material selection, internal supports, foam interiors, ergonomics, stackability, the method of transport and the conditions during storage and transportation.

It is precisely this combination of factors that makes custom packaging valuable. A well-designed package can prevent a product from shifting, vulnerable components from being subjected to unnecessary stress, or accessories from moving freely inside the packaging. At the same time, the internal layout can make work easier for users. Components have a fixed position, missing items are easier to identify, and packing and unpacking become more predictable.

For us, custom packaging is therefore not just about protection. It is also about process reliability.

Practical example: custom packaging for Remade in Holland

Remade in Holland refurbishes products including electric motors and previously transported used mobility scooter motors in cardboard boxes. Together with Faes, the company examined the entire logistics chain and the lifecycle of the packaging.

The analysis showed that reusable custom-made wooden crates were better suited to the application. The crates are specifically designed for the motors and can be used multiple times. As a result, they not only provide better protection during transport but also reduce the amount of packaging waste.

This example demonstrates why custom packaging becomes particularly interesting when you look beyond the initial purchase price. Frequency of use, protection, transport and service life all help determine which packaging solution ultimately offers the best value.

Not every product requires a completely new design. If an existing size is a good match for the product dimensions and intended use, a standard plastic or aluminium case can be a logical choice.

At Faes, we have a dedicated webshop for this: Koffersenkisten.nl. Here we offer standard cases and crates from brands including SKB, HUSK, Viking and Defender.

Standard packaging is particularly suitable when the product fits well within existing dimensions, the protection requirements are straightforward and there are no special requirements relating to the interior, securing the product or its use. A standard case can also provide an excellent starting point when only a relatively simple interior is required.

Most importantly, “standard” does not mean “lower quality”. A high-quality standard case can perform extremely well, provided it is suitable for the application.

The key difference is not about one option being better or worse. It is about the extent to which the packaging is tailored to the product and the process.

Custom packaging provides maximum freedom in terms of dimensions, materials, interior design and functionality. This allows us to design the packaging around specific risks, transport flows and user activities.

Standard packaging uses existing models and sizes. This is efficient when those characteristics already provide everything the product requires.

So the right question is not: is custom packaging better than standard packaging? The right question is: which solution avoids unnecessary complexity while protecting the product in the way the application requires?

At Faes, we look beyond length, width and height. To make the right choice, we assess factors including:

• how fragile the product is;
• how often and in what way it is transported;
• which components need to be packed together;
• who uses the packaging and under what conditions;
• whether it is important to be able to check, remove and return items quickly;
• which requirements apply to storage, stacking or internal transport;
• whether the packaging forms part of a recurring logistics flow.

From there, it often becomes clear whether a standard solution is sufficient or whether custom packaging can add more value.

A measuring instrument that is transported occasionally and fits well inside an existing case model has very different requirements from a complete service kit used every day by several technicians. In the second situation, for example, a custom interior can help position equipment, cables and accessories logically and make it immediately clear whether the kit is complete.

Packaging never stands alone. It is part of a logistics process. That is why we also consider the consequences of a particular choice during actual use.

An oversized standard case, for example, can take up unnecessary space during transport and storage. A case that is too small may require additional padding or extra handling. Conversely, a custom solution only adds value when that additional level of customisation genuinely solves a problem: better protection, more efficient use, fewer handling steps or greater clarity.

That is why, at Faes, we do not design from the perspective of “as much customisation as possible”, but from the function the packaging needs to fulfil.

If an existing case protects the product properly and works well within your process, standard packaging is often an excellent solution. Through Koffersenkisten.nl, we can provide existing plastic and aluminium cases for a wide range of applications.

If there are specific requirements relating to protection, dimensions, internal layout, logistics or use, custom packaging becomes relevant. In that case, Faes develops a packaging solution that not only fits around the product, but also fits the way people work with it.

Are you unsure whether to choose standard or custom packaging? We prefer to start by looking at the application rather than the packaging itself. Based on that, we can determine which solution makes the most sense from both a technical and practical perspective.

What are the main pitfalls when choosing standard packaging?

The biggest pitfall is underestimating product-specific risks such as vibration sensitivity or temperature fluctuations. It is also often forgotten that oversized packaging leads to higher shipping costs and material waste. Always verify that the standard specifications truly align with your product and shipping requirements.

Can standard packaging be adjusted or modified after the fact?

Limited adjustments are possible, such as adding foam inlays or applying extra protective layers. However, structural changes to dimensions or materials are usually not feasible. For significant adjustments, it is more cost-effective to opt for custom packaging from the start.

How do I calculate whether custom packaging will ultimately be cheaper than standard solutions?

Conduct a total cost comparison over the entire lifecycle: initial costs, transportation costs (custom packaging often saves space), risk of product damage, and reuse possibilities. With repeated use of 10+ times, custom packaging is often more cost-effective, especially for valuable or fragile products.

What documentation and certifications are required for packaging in regulated sectors?

For the medical and defense sectors, UN certifications, MIL-STD compliance, and traceability documentation are often required. This includes material testing, shock and vibration certificates, and complete production documentation. Always work with a certified packaging partner who has experience in your specific sector.

How can I optimize the reuse of my packaging for greater sustainability?

Implement a tracking system to monitor the location and condition of packaging, opt for modular designs that can be used for multiple products, and establish clear return processes. Modern digital tools can help track usage and maintenance schedules for maximum lifespan.

What should I do if my product doesn’t fit into available standard packaging?

First, evaluate whether minor adjustments to standard packaging are sufficient, such as custom foam inserts. If this isn’t enough, custom packaging is the best option. Start the development process early and consider modular custom solutions that can also be used for future product variants.